Syllabus - Manufacturing Technology (AB 305)

Automation and Robotics

Manufacturing Technology (AB 305)

III-Semester

UNIT I

METAL CASTING PROCESSES

Sand Casting: Sand Mould, Type of patterns, Pattern Materials, Pattern allowances, Moulding sand Properties and testing, Cores ,Types and applications, Moulding machines, Types and applications; Melting furnaces: Blast and Cupola Furnaces; Principle of special casting processes: Shell, investment, Ceramic mould, Pressure die casting, Centrifugal Casting, CO2 process – Stir casting; Defects in Sand casting

UNIT II

JOINING PROCESSES

Operating principle, basic equipment, merits and applications of: Fusion welding processes: Gas welding, Types, Flame characteristics; Manual metal arc welding, Gas Tungsten arc welding, Gas metal arc welding, Submerged arc welding, Electro slag welding; Operating principle and applications of: Resistance welding, Plasma arc welding, Thermit welding, Electron beam welding, Friction welding and Friction Stir Welding; Brazing and soldering; Weld defects: types, causes and cure.

UNIT III

METAL FORMING PROCESSES

Hot working and cold working of metals, Forging processes, Open, impression and closed die forging ,forging operations. Rolling of metals; Types of Rolling ,Flat strip rolling ,shape rolling operations , Defects in rolled parts. Principle of rod and wire drawing, Tube drawing, Principles of Extrusion , Types; Hot and Cold extrusion.

UNIT IV

SHEET METAL PROCESSES

Sheet metal characteristics, shearing, bending and drawing operations, Stretch forming operations, Formability of sheet metal, Test methods, special forming processes, Working principle and applications, Hydro forming, Rubber pad forming , Metal spinning, Introduction of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming, Micro forming

UNIT V

MANUFACTURE OF PLASTIC COMPONENTS

Types and characteristics of plastics, Moulding of thermoplastics, working principles and typical applications, injection moulding , Plunger and screw machines – Compression moulding, Transfer Moulding, Typical industrial applications – introduction to blow moulding ,Rotational moulding, Film blowing , Extrusion, Thermoforming, Bonding of Thermoplastics.

Course Objective

To introduce the concepts of basic manufacturing processes and fabrication techniques, such as metal casting, metal joining, metal forming and manufacture of plastic components.

Course Outcome

Upon completion of this course, the students can able to 1. Know about metal casting processes and their suitability. 2. Understand the working principle of different welding processes and their applicability 3. Learn about the metal forming processes and their applications 4. Know about sheet metal operations and manufacturing processes of plastics products 5. Apply the different manufacturing process and use this in industry for component production

Practicals

  • Study of different types of patterns

  • Study of casting defects and remidies

  • Fabrication of simple structural shapes using gas welding / arc welding (Lap joint and Butt Joint)

  • Study of welding defects ,causes and remedies

  • Joining of plates and pipes using gas metal arc welding/ arc welding/ submerged arc welding

  • Preparation of green sand moulds by using patterns

  • Manufacturing of simple sheet metal components using shearing and bending operations

  • Manufacturing of sheet metal components using metal spinning on a lathe

Reference Books

  • Hajra Chouldhary S.K and Hajra Choudhury. AK., “Elements of workshop Technology”, volume I and II, Media promoters and Publishers Private Limited, Mumbai

  • Kalpakjian. S, “Manufacturing Engineering and Technology”, Pearson Education India

  • Rao, P.N. “Manufacturing Technology Foundry, Forming and Welding”, 2ndEdition, TMH

  • Raghuwanshi B.S., Workshop Technology ,Dhanpat Rai & Co.